Apparatus, system and method for kitting and automation assembly

ABSTRACT

A method, system and apparatus for a kitting and automation assembly. The system includes an inspection apparatus that captures information of a component. A controller is coupled to the inspection apparatus for receiving and evaluating the information to determine a conforming component. The assembly apparatus includes a datum tool that is operatively configured to contact a datum reference of a part to determine a proper position of the part. The method includes capturing a data set indicative of a characteristic of a component and comparing the data set to a stored data set having a desired characteristic to determine a conforming component. The method also includes picking and positioning the conforming component at an installation position, contacting a datum reference of a part with a datum tool to confirm a proper position, and placing the conforming component on to the part at the proper position.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is based upon and is a divisional of the U.S. patentapplication Ser. No. 14/102,608 filed Dec. 11, 2013. The disclosure ofthe prior application is hereby incorporated in its entirety byreference herein.

BACKGROUND

Current methods of automotive assembly include assembling a kit withautomotive parts. However, there are some automotive parts such as boltsand fasteners required for the kit that are generally not included inthe assembly of the kit but, rather, are picked up and installedindividually by an assembler or an assembly line robot after the kit isassembled. This is an inefficient and time consuming process due, atleast in part, to incorrect bolts, misplaced parts and incorrectlyplaced bolts.

SUMMARY

In one aspect, a kitting and automation assembly process includes amethod involving the steps of scanning a component and capturing a dataset indicative of a characteristic of the component. The method furtherinvolves comparing the captured data set with a stored data set having adesired characteristic and determining that the component is aconforming component if the data set matches the desired characteristicsof the stored data set. Thereafter, picking and positioning theconforming component at an installation position with respect to a partby contacting a datum reference of the part with a tool. The tool havinga datum finder configured to locate the datum reference at a properalignment. The tool subsequently generates a signal confirming the toolhas made contact with the datum reference at the proper alignment.

In another aspect, a kit inspection system includes an inspectionapparatus. The inspection apparatus having a tool configured to scan acomponent and capture data indicative of characteristics of thecomponent. A controller having a stored data set establishing a desiredcharacteristic that defines a conforming component is coupled to theinspection apparatus for receiving and comparing the data set with thestored data set to determine a conforming component.

In still another aspect, a pick and place apparatus having a tool with adatum finder is configured to make contact with a datum reference of awork part. The pick and place apparatus further includes a controllercoupled to the tool having a stored data set that establishes a properposition of the work part. The pick and place apparatus further includesa part holder to pick and place a component onto a part at aninstallation position.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and other aspects of the present disclosure will becomeapparent to those skilled in the art to which the present disclosurerelates upon reading the following description with reference to theaccompanying drawings, in which:

FIG. 1 is a partly schematic illustration of an exemplary kittingarrangement and automation process according to an embodiment.

FIG. 2 is a block diagram of an inspection system according to anembodiment.

FIG. 3 is a side view of an exemplary inspection apparatus according toan embodiment.

FIG. 4 is an exemplary illustration of an output of inspectioninformation.

FIG. 5 is another exemplary illustration of an output of inspectioninformation.

FIG. 6 is a block diagram of a pick and place system according to anembodiment.

FIG. 7 is a sectional side view of an exemplary assembly apparatusaccording to an embodiment.

FIG. 8 is a side view of an exemplary fastening tool according to anembodiment

FIG. 9 is a flow chart of an exemplary process for the pick and placesystem of FIG. 6.

DETAILED DESCRIPTION

Examples will now be described more fully hereinafter with reference tothe accompanying drawings in which example embodiments are shown.Whenever possible, the same reference numerals are used throughout thedrawings to refer to the same or like parts. However, aspects may beembodied in many different forms and should not be construed as limitedto the embodiments set forth herein.

Referring now to FIG. 1, a schematic illustration of an exemplarykitting arrangement and automation process 1 for inspecting andassembling components according to an embodiment. The process 1 utilizesan inspection system 10 for scanning and evaluating a component 3retained within kit tray 5, wherein the kit tray 5 has previously beensupplied with one or more components 3. The kit tray 5 may containvarious parts or components such as, for example, automotive parts to beassembled. As used herein, the terms “part” and “component” areinterchangeable. The kit tray 5 may also contain fasteners such as, forexample, bolts or screws to be used to assemble the automotive parts.Accordingly, the inspection system 10 may capture information indicativeof a characteristic of the component 3 and may evaluate the informationrelative to a stored set of data. The inspection system 10 may determinewhether to accept the kit tray 5, thereafter outputting a conforming kittray 55 containing a component 53, wherein the component 53 is one thathas been accepted by the inspection system 10.

The process 1 further utilizes a pick and place system 100 configured toreceive the conforming kit tray 55, wherein the conforming kit tray 55may be the kit tray 5 that passed through the inspection system 10. Inthe alternative, the conforming kit tray 55 may not be the kit tray 5,but rather may contain a component 53 matching a characteristic of anacceptable component for the process 1. The pick and place system 100 isoperatively configured to pick the component 53 from the conforming kittray 55 and find a target installation position to place and install thecomponent 53 on to a part 54.

FIG. 2 is a block diagram of an exemplary inspection system 10 that willbe used to describe the features of the inspection system 10 in detailaccording to an embodiment. The inspection system 10 includes aninspection apparatus 20 that is operatively coupled to a controller 40to transmit and receive information. The inspection apparatus 20 isoperable to generate information about a component 3 undergoinginspection. Accordingly, the inspection apparatus 20 includes a holder22, such as a robot or robot arm, and an examination tool 30 having oneor more examining devices configured to inspect or scan the component 3.One skilled in the art will readily appreciate that the examiningdevices may be a camera 32, a laser 34, or any other suitable examiningdevices of the sort.

The controller 40 is operatively coupled to the inspection apparatus 20to receive the information generated by the inspection apparatus andstore or transmit data corresponding to the generated information. Thecontroller 40 further includes a memory 42 that is coupled to aprocessor 44 to evaluate the information generated by the inspectionapparatus 20. The processor 44 could be a central processor unit, amicroprocessor, an application-specific instruction-set processor, adigital signal processor, a specialized microprocessor, a dataprocessor, an audio processor or the like. A user interface 46 such amonitor, a key pad, a touch panel or the like is connected to or incommunication with the memory 42 to relay a stored data set pertainingto the component. Prior to the inspection of a component, a user mayselect the stored data set from memory 42 or enter data pertaining tothe component 3 into the controller 40 using the user interface 46 toenter information into the inspection system 10. The memory 42 mayinclude a data storage device, such as a flash drive, or an optical diskdrive operable to read the stored data set for the component 3 from thedata storage device.

Turning to the operation of the inspection system 10 according to anembodiment, the kit tray 5 containing one or more components 3 isreceived by the inspection system 10. The tool 30 is operativelymanipulated by the controller 40 to generate inspection information andperform measurements of the components 3. For example, the generatedinspection information may include information pertaining to the absenceof a component, information pertaining to the improper loading of acomponent, or information pertaining to the inclusion of an incorrectcomponent, a combination of all this information, or the like. If thecomponent 3 is a fastener for example, the measurements may also includedimensional measurements such as information about a bolt height orinformation about a bolt diameter. The controller 40 in communicationwith the processor 44 transmits the inspection information generated bythe inspection apparatus 20 to the processor 44, which may performpre-programmed routines, including the generation and compilation ofstatistical information based upon the transferred quality inspectionand dimensional information.

The processor 44 may also perform pre-programmed comparison routineswherein the dimensional measurements are compared to a stored data setin the memory 42 pertaining to the component selected by the userinterface 46 in order to determine a component 53 that is acceptable tothe inspection system. The stored data set contains a desiredcharacteristic that defines a conforming component such as, for example,an upper and lower tolerance limit for the height of an acceptablecomponent or the orientation of a conforming component. In oneembodiment, the processor 44 is configured to continuously generatemeasurement information and directly provide the information to theuser. The user may view the image and measurement information generatedby the inspection apparatus 20 using a display device such as a monitor,a printer, or other similar devices. In another embodiment, theprocessor 44 is configured to accept or to reject the kit tray 5 basedon whether the generated measurement information of the component 3matches the desired characteristics of the stored data set or fallswithin a pre-determined tolerance limits. In another embodiment, theprocessor may cause the inspection apparatus 20 to pause its operationwhen the component 3 does match the desired characteristics of thestored data in the memory 42 pertaining to the component selected by theuser interface 46.

FIG. 3 is a side view of an exemplary inspection apparatus that will beused to describe the inspection apparatus 20 in greater detail accordingto an embodiment. The inspection apparatus 20 comprises a robot arm 26positioned to rotatably support an examination tool 30 having at leastone examining device to examine the component 3. In one embodiment, thetool 30 comprises a camera 32 and a laser 34 affixed to a surface of thetool 30. The robot arm 26, the camera 32 and the laser 34 are incommunication with the processor 44; for example, they may each includea digital data port that is electrically coupled to the controller 40 totransfer digital data to the processor 44. The inspection apparatus 20is configured to receive the kit tray 5 containing the component 3 toundergo inspection. In an alternate embodiment, the kit tray 5 may beadapted to have an adjustable plate and operatively coupled to theinspection apparatus 20 such that the inspection apparatus 20 maydetermine the height of a component 3 within the kit tray 5 relative tothe adjustable plate of the kit tray 5 when the component 3 undergoesinspection.

Still referring to FIG. 3, a z-axis is substantially perpendicular tothe mounting surface of the tool 30. The camera 32 captures an image ofthe kit tray 5 and the components 3. The laser 34 projects a beamsubstantially parallel to the z-axis on to the kit tray 5 generatinginformation concerning the components 3, for example, a dimensionalcharacteristic of the component 3 such as the height of the fastener.The generated z-axis information is communicated to the controller 40relaying varying information according to exemplary embodiments depictedby FIG. 4 and FIG. 5.

The camera 32 may output an image, for example, as shown in FIG. 4 on toa display device at the user interface 46 showing a captured image withinspection information 48 of the components 3 and of the kit tray 5. Thecaptured image with inspection information 48 may relay informationabout the components 3 pertaining to linear displacement, such asincorrect position or incorrect orientation of a component (e.g., parttilted). The captured image with inspection information 48 may alsorelay the absence of a component (e.g., bolt missing). The inspectioninformation may indicate a component as acceptable or unacceptable, forexample, by words (e.g., OK for good and NG for no good), color (e.g.,green for good and red for no good), highlighted areas, or any otherindicators.

In a similar manner, the beam projected by laser 34 may be used togenerate a graphic representation, for example, as shown in FIG. 5 fordisplay on a display device at the user interface 46 for showinggraphical data with inspection information 50 of the component 3. Thegraphical data with inspection information 50 may relay information suchas, the presence of a component 3, or indicate information pertaining tothe dimensional characteristic of the component, such as whether theheight of a component 3 above the adjustable plate or surface of the kittray 5 falls within a pre-set upper and lower limit, or other qualityinformation of the sorts. For example, if the component is above anupper height limit or below a lower height limit, then the inspectionsystem will determine the component is the incorrect size and indicatethat it is a no good (NG) part.

FIG. 6 a block diagram of the pick and place system 100 will be used todescribe the features of the pick and place system 100 in detailaccording to an embodiment. The pick and place system 100 includes aninstallation or assembly apparatus 120 that is operatively coupled to acontroller 140 to transmit and receive information. The assemblyapparatus 120 is operable to pick and place a component 53 to beinstalled on to a work part 54, wherein the component 53 may be apartial engine or automotive part, for example, a water pump havingfasteners such as bolts or screws retained within the water pump, andthe part 54 may be a corresponding engine or automotive part thattogether with the component 53 make a whole engine or automotive part.In the illustrated embodiment, the part 54 is positioned within theconforming kit tray 55. In an alternate embodiment, the part 54 may notbe with the conforming kit tray 55, rather separately supplied to thepick and place system 100.

The assembly apparatus 120 includes a datum tool 122 having at least onedatum finder configured to locate a datum reference on the part 54. Thedatum reference serves as a locating or positioning feature for thedatum tool 122 and could be, for example, a hole, a slot, a peg or arivet situated on a surface of the part 54. The datum reference may becreated during the manufacturing of the part 54. One skilled in the artwill appreciate the datum reference may be created differently dependingon the requirements and functionality of the work part. The assemblyapparatus 120 also includes a part holder 124 operatively configured topick up and retain at least one component 53 to be installed. Theassembly apparatus 120 further includes a fastening tool 126 operativelyconfigured to install the component 53 on to the part 54.

The controller 140, operatively coupled to the assembly apparatus 120,includes a memory 142 that is coupled to a processor 144 and a userinterface 146. Prior to the installation of the component 53 to the part54, a user may select or enter data pertaining either the component 53or the part 54 into the controller 140 using the user interface 146 toenter information into the pick and place system 100. The memory 142 maybe a data storage device, such as a flash drive, or an optical diskdrive operable to read the data for a work part from the data storagedevice.

FIG. 7 is a sectional view of an exemplary assembly apparatus that willbe used to describe the features of the assembly apparatus 120 accordingto an embodiment. The assembly apparatus 120 comprises a datum tool 122having datum finders 123 operatively configured to locate or contactdatum references positioned on surfaces of the part 54. One skilled inthe art will appreciate that datum finders may have tolerance limitsspecified to them to accommodate variations to the datum referenceswhich can occur in the manufacturing of the part 54. The datum findermay be a feature such as, for example a pin, plate, pad, lug or anyother features of the sorts. In the illustrated embodiment, the datumtool 122 comprises a first datum finder 123 a and a second datum finder123 b. The first datum finder 123 a may be a pad as shown and isconfigured to contact a first surface of the part 54. The second datumfinder 123 b may be a pin as shown, and is configured to contact asecond surface of the part 54. In an embodiment, the first datum 123 afinder is configured to contact a vertical surface of the part 54, whilethe second datum finder 123 b is configured to contact a horizontalsurface of the part 54. The first datum finder 123 a and second datumfinder 123 b may concurrently contact the part 54 or may separatelycontact the part 54. The datum tool 122 further comprises a sensor (notshown) in communication with the controller 140. The sensor isconfigured to generate a signal when the datum tool 122 locates or makescontact with the datum reference and transmit the signal to thecontroller 140. The assembly apparatus 120 further comprises a partholder 124 operable to pick and retain the component 53. The part holderis configured to retain the component 53 that may, for example, be anautomotive part having a bolt or fastener retained. The part holder 124is operatively coupled to the controller 140 to transfer and receivedigital signals; for example, the part holder 124 may include a digitaldata port that is electrically coupled to the controller 140 to receivethe signal from the datum tool 122. Upon receiving the signal, the partholder 124 places the component on to the part 54 at the installationposition. The assembly apparatus 120 further comprises a fastening tool126 operable to install the component 53 on to the part 54.

FIG. 8 is a side view of an exemplary fastening tool that will be usedto describe the fastening tool 126 in greater detail according to anembodiment. The fastening tool 126 comprises a plurality of spindles128. In an embodiment, the spindles 128 may be spring loaded. Eachspindle 128 is attached to a motor 130 via a chain drive. Each spindle128 further has a clutch 132 to engage and disengage each spindle 128independently. As such, the chain drive can simultaneously rotate eachof the spindles 128. The fastening tool 126 further comprises a datumlocator 134 configured to locate a datum target on a part 54. Oneskilled in the art will appreciate that the datum target may be the samedatum reference used by the datum tool 122 or may be adaptedparticularly for the datum locator 134. The datum target may be usedeither as a secondary confirmation of the proper position of the part 54or a backup check for the proper position in the event that part of theassembly apparatus is inoperative. The fastening tool 126 may beconfigured to independently engage a fastener retained in the component53 and simultaneously secure the fastener to the part 54. In theillustrated embodiment, each spindle 128 grips a fastener 136 retainedwithin the component 53 when the component 53 is pick from theconforming kit tray 55 and prepares for the installation of the fastenerwhen the component 53 is on the part 54. As the spindles are rotated,the captured fasteners will rotate thus attaching the component 53 tothe part 54 at the installation position.

Referring now to FIG. 9, a flow diagram illustrating a sequence ofoperations by a pick and place system 100 for installing a component 53on to a part 54 according to an embodiment. In step S102 the pick andplace system 100 receives a conforming kit tray 55, wherein theconforming kit tray 55 is an accepted kit tray 5 following theinspection system 10. In an alternative embodiment, the conforming kittray 55 may have bypassed the inspection system 10 and, for example,undergone manual inspection. In step S104 the part holder 124 picks acomponent 53 from the conforming kit tray 55 and positions the component53 at an installation position, wherein the installation position is apre-determined position that may be different depending on either thecomponent 53, or the part 54, or an arbitrary position in space. In stepS106 the datum tool 122 having at least one datum finder 123 configuredto locate a datum reference, locates or makes contact with at least onedatum reference on the part 54. In optional step S107, it may bedetermined the datum tool 122 did not locate or make contact with adatum reference on the part 54 thereby stopping the operation of thepick and place system 100 to realign the part 54. In an alternateembodiment, the pick and place system 100 may reject the part 54 andcontinue operation of the pick and place system 100. In yet anotherembodiment, the pick and place system 100 may retry to contact a datumreference on the part 54. If the datum tool 122 does locate or makecontact with a datum reference, the datum tool 122 generates a signalenabling the system 100 to proceed to step S108. In step S108 the partholder 124 places the component 53 on to the part 54 at the installationposition. In step S110 the fastening tool 126 installs the component 53on to the part 54. One skilled in the art will readily appreciate thatthe order of the steps in FIG. 9 may vary and the association betweenthe features of the system may be different.

Many other example embodiments can be provided through variouscombinations of the above described features. Although the embodimentsdescribed hereinabove use specific examples and alternatives, it will beunderstood by those skilled in the art that various additionalalternatives may be used and equivalents may be substituted for elementsand/or steps described herein, without necessarily deviating from theintended scope of the application. Modifications may be necessary toadapt the embodiments to a particular situation or to particular needswithout departing from the intended scope of the application. It isintended that the application not be limited to the particular exampleimplementations and example embodiments described herein, but that theclaims be given their broadest reasonable interpretation to cover allnovel and non-obvious embodiments, literal or equivalent, disclosed ornot, covered thereby.

What is claimed is:
 1. A pick and place apparatus for securing acomponent to a part, the apparatus comprising: a tool including a datumfinder, the tool being configured to contact the datum finder with adatum reference of a part to confirm that the component is at aninstallation position with respect to the part, wherein the datumreference defines a present position of the part; a controlleroperatively coupled to the tool, the controller having a stored data setestablishing a proper position of the part, wherein the tool transmits asignal when the datum finder of the tool makes contact with the datumreference; a part holder having at least one spindle configured toengage with a fastener retained on the component, wherein the datumfinder is located radially inward with respect to the spindle, whereinthe part holder is in operative communication with the controller, andthe part holder is adapted to pick and retain the component at aninstallation position, wherein the part holder places the component onto the part at the installation position upon receiving the signal thatthe datum finder has made contact with the datum reference of the part,and the part holder is configured to engage the at least one spindlewith a fastener retained on the component.
 2. The pick and placeapparatus according to claim 1, wherein the at least one spindlecomprises a plurality of spindles operatively coupled to the partholder, wherein the plurality of spindles are configured to install thecomponent on to the part.
 3. The pick and place apparatus according toclaim 2, wherein each one of the plurality of spindles is adapted toindependently engage a fastener retained in the component andsimultaneously secure the fastener to the part when the datum finder hasmade contact with the datum reference of the part.
 4. The pick and placeapparatus according to claim 1, wherein the datum finder furthercomprises first portion and a second portion, wherein the first portionis configured to make contact with a first surface of the part, thesecond portion is configured to make contact with a second surface ofthe part.
 5. The pick and place apparatus according to claim 1, whereinthe tool includes a sensor configured to transmit the signal when thetool makes contact with the datum reference.